Subsea bop control system with dual-action check valve

ABSTRACT

A subsea hydraulic system comprises a dual (or dual action) check valve on a port for connection to a remotely operated vehicle (ROV). The check valve provides backpressure to flow in either direction. This keeps hydraulic fluid in the hydraulic system, and seawater out. If flow needs to return to the ROV, it may flow out the port, subject to a selected back pressure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/208,658 filed on Dec. 4, 2018 (now issued as U.S. Pat. No.10,415,715), which is a continuation of U.S. application Ser. No.16/046,074 filed on Jul. 26, 2018, (now issued as U.S. Pat. No.10,174,857) which is a continuation of U.S. application Ser. No.15/723,980 filed on Oct. 3, 2017, (now issued as U.S. Pat. No.10,054,239) which is a continuation U.S. application Ser. No. 15/255,379filed on Sep. 2, 2016, (now issued as U.S. Pat. No. 9,810,336) whichclaims the benefit of U.S. Provisional Application No. 62/239,085, filedon Oct. 8, 2015, the contents of which are hereby incorporated byreference in their entireties.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention generally relates to subsea equipment for oil andgas production. More particularly, it relates to subsea blow-outpreventers (BOPs) and other such hydraulically actuated equipment.

2. Description of the Related Art Including Information Disclosed Under37 CFR 1.97 and 1.98

A blow out preventer is a piece of hydraulically operated equipment usedto close in a well (in an emergency) fitted around a drill string orproduction riser.

In essence, a BOP is a large valve at the top of a well that may beclosed if the drilling crew loses control of formation fluids. Byclosing this valve (usually operated remotely via hydraulic actuators),the drilling crew usually regains control of the reservoir, andprocedures can then be initiated to increase the mud density until it ispossible to open the BOP and retain pressure control of the formation.BOPs come in a variety of styles, sizes and pressure ratings. Some caneffectively close over an open wellbore, some are designed to sealaround tubular components in the well (drillpipe, casing or tubing) andothers are fitted with hardened steel shearing surfaces that canactually cut through drillpipe. Since BOPs are critically important tothe safety of the crew, the rig and the wellbore itself, BOPs areinspected, tested and refurbished at regular intervals determined by acombination of risk assessment, local practice, well type and legalrequirements. BOP tests vary from daily function testing on criticalwells to monthly or less frequent testing on wells thought to have lowprobability of well control problems.

Although typically controlled from the surface via umbilical lines,subsea BOPs often are equipped with a hydraulic port for connection toan underwater remotely operated vehicle (ROV). In this way, if the BOPcannot be closed via the surface controls, hydraulic fluid (underpressure) supplied by an ROV connected to the BOP control circuits maybe able to close the BOP.

In any subsea hydraulic connection, there is a risk that seawater mayenter the hydraulic system and contaminate it and there is a risk thathydraulic fluid may leak out of the hydraulic connection and contaminatethe marine environment. In the past, ROV ports have been plugged, manualvalves which can be actuated by a ROV have been used, and conventionalsingle check valves have been used to address this problem. None of thepreviously tried solutions mentioned above will permit return flow outof the ROV port. The present invention addresses this problem in a novelway.

BRIEF SUMMARY OF THE INVENTION

In subsea ROV ports, problems may exist with seawater entering thehydraulic system and/or hydraulic fluid being discharged into the sea. Adual-action check valve according to the invention provides backpressureto flow in either direction. This keeps hydraulic fluid in the hydraulicsystem, and seawater out. If flow needs to return out the ROV port, itis free to flow out the port, subject to a back pressure determined by acombination of the hydrostatic pressure and the spring rate of thepoppet spring.

In certain embodiments of the present invention, two check valves areconfigured so that flow can occur in either direction, subject to a backpressure which may be varied by selection by the spring rate(s) ofspring-loaded poppet valves within the apparatus. In another embodiment,a single dual-acting valve allows flow to occur in either direction,subject to back pressures that may be determined by the selection ofsprings having certain spring rates.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 is a schematic diagram of a subsea BOP hydraulic system accordingto one embodiment of the invention.

FIG. 2A is a cross-sectional view of a first embodiment of a dual-actioncheck valve according to the invention.

FIG. 2B is a cross-sectional view of a second embodiment of adual-action check valve according to the invention.

FIG. 3A is a cross-sectional view of a third embodiment of a dual-actioncheck valve according to the invention.

FIG. 3B is a cross-sectional view of a fourth embodiment of adual-action check valve according to the invention.

FIG. 4A is a cross-sectional view of a fifth embodiment of a dual-actioncheck valve according to the invention.

FIG. 4B is a cross-sectional view of a sixth embodiment of a dual-actioncheck valve according to the invention.

FIG. 5 is a cross-sectional view of a seventh embodiment of adual-action check valve according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention may best be understood by reference to the accompanyingdrawing figures which illustrate various, representative embodiments ofthe invention.

Referring first to FIG. 1, a subsea BOP control system equipped with adual-action check valve according to the invention is shownschematically. Subsea BOP control system 100 comprises offshore platform101 having hydraulic fluid reservoir [supply tank] 102 in fluidcommunication with motor-driven hydraulic pump 103 which may supplyhydraulic fluid under pressure to hydraulic accumulators 107 viahydraulic umbilical 104.

Electrical signal line 105 controls solenoid valve 106 which receivespressurized hydraulic fluid from pilot pressure regulator 108. Whenselected “open” via signal line 105, solenoid valve 106 suppliespressurized hydraulic fluid to open sub-plate mounted valve 109. In the“open” state, sub-plate mounted valve 109 allows pressurized hydraulicfluid from drilling pressure regulator 110 to flow to shuttle valve 111and thence to closing circuit 115 of BOP 112. Closing circuit 115directs pressurized hydraulic fluid to the indicated sides of pistons114 causing ram closure members 113 to seal the well. As isconventional, pressurized hydraulic fluid may be directed to theindicated sides of pistons 114 via opening circuit 116 to withdraw ramclosure members 113 thereby opening BOP 112.

Subsea BOP control system 100 provides two additional means for closingBOP 112. Shuttle valve 117 allows pressurized hydraulic fluid to besupplied to closing circuit 115 by a redundant hydraulic system or,alternatively, by a remotely operated vehicle (ROV) via dual-actioncheck valve 120 and ROV port 130. Dual-action check valve 120 providesbackpressure to fluid flow in either direction. This keeps hydraulicfluid in the hydraulic system, and seawater out.

Referring now to FIG. 2A, a first embodiment 220 of dual-action checkvalve 120 in FIG. 1 is illustrated.

Dual-action check valve 220 comprises body 212 having first end 201 andopposing second end 202. Body 212 may be made of any suitable materialand may be any suitable shape. In one particular preferred embodiment,body 212 is fabricated of 316L stainless steel. In the illustratedembodiment, body 212 is generally cylindrical.

First port 203 and second port 204 are provided opposite one another inthe side of body 212. First port 203 and/or second port 204 may beinternally threaded for connection to hydraulic lines or conduits.

First blind bore 214 is provided in first end 201 of body 212. Secondblind bore 216 is provided in second end 202 of body 212. First blindbore 214 and second blind bore 216 may have sections of different insidediameter (i.d.) with inclined shoulders 231 connecting the differentsections. First blind bore 214 and second blind bore 216 may be sealedby plugs 205.

First cross bore 218 interconnects first blind bore 214, second blindbore 216 and second port 204 as shown. Second cross bore 219interconnects first blind bore 214, second blind bore 216 and first port203 as shown.

Poppet valves 254 are provided in first blind bore 214 and second blindbore 216. Poppet valves 254 are urged to seat against inclined shoulders231 by poppet springs 250 which act against spring collars 228 securedby plugs 205.

In operation, if hydraulic fluid enters port 203 with sufficientpressure to open poppet valve 254 in bore 216, it may flow via crossbore 218 and exit at port 204. Conversely, if hydraulic fluid entersport 204 with sufficient pressure to open poppet valve 254 in bore 214,it may flow via cross bore 219 and exit at port 203. It will beappreciated by those skilled in the art that the pressure required toopen poppet valves 254 depends both upon the closing force of poppetsprings 250 and the pressure of the fluid on the opposite side of poppetvalve 254. The poppet valve 254 in bore 214 may have the same or adifferent spring rate than the poppet valve 254 in bore 216. Byselecting different spring rates, the check valve opening pressure in afirst direction may be made different from the check valve openingpressure in an opposing second direction.

A second embodiment 221 of dual-action check valve 120 in FIG. 1 isillustrated in FIG. 2B. This embodiment is substantially the same as thefirst embodiment illustrated in FIG. 2A and described, above. However,in the second embodiment, dual-action check valve 221 is provided withplugs 206 having an integral spring seat comprised of recess 207. Thiseliminates the need for spring collars 228 which both reduces the partscount of dual-action check valve 221 relative to that of dual-actioncheck valve 220 and permits the longitudinal dimension of body 212′ tobe less than that of body 212 thereby reducing the size, weight andmaterial required for the device.

Referring now to FIG. 3A, a third embodiment 320 of dual-action checkvalve 120 in FIG. 1 is illustrated.

Dual-action check valve 320 comprises body 312 having first end 301 andopposing second end 302. Body 312 may be made of any suitable materialand may be any suitable shape. In one particular preferred embodiment,body 312 is fabricated of 316L stainless steel. In the illustratedembodiment, body 312 is generally cylindrical.

First port 303 and second port 304 are provided opposite one another inthe side of body 312. First port 303 and/or second port 304 may beinternally threaded for connection to hydraulic lines or conduits.

First blind bore 314 is provided in first end 301 of body 312. Secondblind bore 316 is provided in second end 302 of body 312. First blindbore 314 and second blind bore 316 may have sections of different insidediameter (i.d.) with inclined shoulders 331 connecting the differentsections 314 to 314′ and 316 to 316′). First blind bore 314 and secondblind bore 316 may be sealed by plugs 305.

Dual-action check valve 320 is equipped with cross-flow pieces 340situated between plugs 305 and spring collars 328. Cross-flow pieces 340may have a generally cylindrical body sized to fit within bores 314 and316 and a central axial bore 342. The outer cylindrical surface ofcross-flow pieces 340 may have annular recess 344. Internal radial ports346 provide fluid communication between annular recess 344 and centralaxial bore 342.

First cross bore 318 interconnects first blind bore 314′, second blindbore 316 (at the location of cross-flow piece 340) and second port 304as shown. Second cross bore 319 interconnects first blind bore 314 (atthe location of crossflow piece 340), second blind bore 316′ and firstport 303 as shown.

Poppet valves 354 are provided in first blind bore 314 and second blindbore 316. Poppet valves 354 are urged to seat against inclined shoulders331 by poppet springs 350 which act against spring collars 328 securedby plugs 305.

In operation, if hydraulic fluid enters port 303 with sufficientpressure to open poppet valve 354 in bore 316, it may flow via crossbore 318 and exit at port 304. Conversely, if hydraulic fluid entersport 304 with sufficient pressure to open poppet valve 354 in bore 314,it may flow via cross bore 319 and exit at port 303. It will beappreciated by those skilled in the art that the pressure required toopen poppet valves 354 depends both upon the closing force of poppetsprings 350 and the pressure of the fluid on the opposite side of poppetvalve 354. The poppet valve 354 in bore 314 may have the same or adifferent spring rate than the poppet valve 354 in bore 316. Byselecting different spring rates, the check valve opening pressure in afirst direction may be made different from the check valve openingpressure in an opposing second direction.

A fourth embodiment 321 of dual-action check valve 120 in FIG. 1 isillustrated in FIG. 3B. This embodiment is substantially the same as thethird embodiment illustrated in FIG. 3A and described, above. However,in the fourth embodiment, dual-action check valve 321 has a shorter body312′ made possible by reducing the lengths of first blind bore section314′ and second blind bore section 316′. In this way, the size, weightand material required for the device may be reduced.

Referring now to FIG. 4A, a fifth embodiment 420 of dual-action checkvalve 120 in FIG. 1 is illustrated.

Dual-action check valve 420 comprises body 412 having first end 401 andopposing second end 402. Body 412 may be made of any suitable materialand may be any suitable shape. In one particular preferred embodiment,body 412 is fabricated of 316L stainless steel. In the illustratedembodiment, body 412 is generally cylindrical.

First blind bore 414 is provided in first end 401 of body 412. Secondblind bore 416 is provided in second end 402 of body 412. First blindbore 414 and second blind bore 416 may have sections of different insidediameter (i.d.) with inclined shoulders 431 connecting the differentsections 414 to 414′ and 416 to 416′). First blind bore 414 and secondblind bore 416 may be provided with threaded retainers 460. Retainers460 have a central axial bore 462 a portion of which may be internallythreaded to form first port 403 and second port 404.

Dual-action check valve 420 is equipped with cross-flow pieces 440situated between retainers 460 and spring collars 428. Cross-flow pieces440 may have a generally cylindrical body sized to fit within bores 414and 416 and a central axial bore 442. The outer cylindrical surface ofcross-flow pieces 440 may have annular recess 444. Internal radial ports446 provide fluid communication between annular recess 444 and centralaxial bore 442.

First angled internal cross bore 415 interconnects first blind bore 414′and second blind bore 416 (at the location of cross-flow piece 440) asshown. First angled internal cross bore 415 is also in fluidcommunication with second port 404 (via cross-flow piece 440 in bore416). Second angled internal cross bore 417 interconnects first blindbore 414 (at the location of cross-flow piece 440) and second blind bore416′, as shown. Second angled internal cross bore 417 is in fluidcommunication with first port 403 (via cross-flow piece 440 in bore414). Bores 414 and 416 may be sized and spaced so as to permit angledinternal cross bores 415 and 417 to be drilled through the openings inthe ends 401 and 402 of body 412 created by blind bores 414 and 416.

Poppet valves 454 are provided in first blind bore 414 and second blindbore 416. Poppet valves 454 are urged to seat against inclined shoulders431 by poppet springs 450 which act against spring collars 428 securedby retainers 405.

In operation, if hydraulic fluid enters port 403 and second angledinternal cross bore 417 with sufficient pressure to open poppet valve454 in bore 416, it may flow through cross-flow piece 440 in bore 416and exit at port 404. Conversely, if hydraulic fluid enters port 404 andfirst angled internal cross bore 415 with sufficient pressure to openpoppet valve 454 in bore 414, it may flow through cross-flow piece 440in bore 414 and exit at port 403. It will be appreciated by thoseskilled in the art that the pressure required to open poppet valves 454depends both upon the closing force of poppet springs 450 and thepressure of the fluid on the opposite side of poppet valve 454. Thepoppet valve 454 in bore 414 may have the same or a different springrate than the poppet valve 454 in bore 416. By selecting differentspring rates, the check valve opening pressure in a first direction maybe made different from the check valve opening pressure in an opposingsecond direction.

A sixth embodiment 421 of dual-action check valve 120 in FIG. 1 isillustrated in FIG. 4B. This embodiment is substantially the same as thefifth embodiment illustrated in FIG. 4A and described, above. However,in the sixth embodiment, dual-action check valve 421 has spring collars428 secured in bores 414 and 416 with retainer clips 429 and theportions of bores 414 and 416 proximate ends 401 and 402, respectively,are internally threaded for connection to hydraulic lines or conduits.This eliminates the need for retainers 460. In this way, the size,weight and material required for the device may be reduced.

Referring now to FIG. 5, a seventh embodiment of a two-way check valveaccording to the present invention is shown that comprises a singlepoppet valve.

2-way check valve 500 comprises body 512 having first end 501 andopposing second end 502. Body 512 may be made of any suitable materialand may be any suitable shape. In one particular preferred embodiment,body 512 is fabricated of 316L stainless steel. In the illustratedembodiment, body 512 is generally cylindrical.

First port 503 is provided in first end 501 of body 512 and second port504 is provided in second end 502 of body 512. Ports 503 and 504 may beinternally threaded for connection to hydraulic fluid lines and/orconduits.

Sleeve 539 is in sliding engagement with central axial bore 537 of body512. The first end of the sleeve has an inclined face 541 that abutsinclined shoulder 531 in the bore. The second end of the sleeve, when inthe closed position shown in FIG. 5, is spaced from spring collar 528which is held in the bore with retainer clip 529. Spring collar 528includes at least two passages 524 therethrough and an actuator 525extending longitudinally therefrom. When sleeve 539 moves longitudinallyso that inclined face 541 is spaced away from inclined shoulder 531,actuator 525 opens poppet valve 554 by contacting poppet valve actuator556. Sleeve 539 is urged longitudinally toward the spring collar 528 bythe pressure of hydraulic fluid acting on the sleeve through second port504. Thus, hydraulic fluid entering port 504 and flowing through bore537 urges sleeve 539 axially until the sleeve contacts spring collar528. When sleeve 539 moves axially, actuator 525 blocks the poppet valveand forces the poppet valve open to allow hydraulic fluid to movethrough passageway 549 in the sleeve and through passages 524 in thespring collar.

To keep the valve closed in the absence of hydraulic pressure enteringsecond port 504, spring 544 is positioned in bore section 548 withinsleeve 539. Spring 544 biases the sleeve to the closed position whereinclined face 541 is engaged to inclined shoulder 531. At anintermediate location on sleeve 539 seal 532 provides a sliding fluidseal between the outer circumference of the sleeve and the bore in thecoupling member. Seal 532 may comprise an O-ring flanked by backupseals.

If hydraulic fluid pressure in the fluid lines connected to first port503 exceeds a predetermined level, the pressure urges poppet valve 554away from valve seat 534 in sleeve 539, compressing spring 550 to allowthe flow of hydraulic fluid through the dual-action check valve in afirst direction. Spring 550 may be held in place by spring collar 535which includes a central passage therethrough and a retainer clip 536 tohold the spring collar in place. Spring 544 may be selected to have thesame or a different spring rate [strength] than spring 550.

The dual-action check valve illustrated in FIG. 5 is utilized as a bleedvalve in the undersea hydraulic coupling member disclosed in U.S. Pat.No. 6,474,359 to Robert E. Smith, III. The disclosure of U.S. Pat. No.6,474,359 is hereby incorporated by reference in its entirety. In anembodiment, the dual-action check valve illustrated in FIG. 5 may beincorporated into a male hydraulic coupling member as disclosed in U.S.Pat. No. 6,474,359 and could thereby comprise both ROV port 130 anddual-action check valve 120 in the BOP control system illustrated inFIG. 1 for use with ROVs having a female hydraulic coupling member. Inyet another embodiment, the two-way check valve of FIG. 5 may beincorporated into a female hydraulic coupling member configured forconnection to an ROV having a corresponding male hydraulic couplingmember.

The foregoing presents particular embodiments of a system embodying theprinciples of the invention. Although particular embodiments of thepresent invention have been shown and described, they are not intendedto limit what this patent covers. One skilled in the art will understandthat various changes and modifications may be made without departingfrom the scope of the present invention as literally and equivalentlycovered by the following claims.

1-11. (canceled)
 12. A subsea valve apparatus for communicatinghydraulic fluid with first and second hydraulic elements, the apparatuscomprising: a body having first and second external ports and havingfirst and second internal bores, the first external port incommunication with the first hydraulic element, the second external portin communication with the second hydraulic element; a first shoulderdefined in the first bore and separating a first proximal section of thefirst bore from a first distal section; a second shoulder defined in thesecond bore and separating a second proximal section of the second borefrom a second distal section; a first cross bore defined in the body,the first cross bore in fluid communication with the first external portof the body and interconnecting the second distal section with the firstproximal section; a second cross bore defined in the body, the secondcross bore in fluid communication with the second port of the body andinterconnecting the first distal section with the second proximalsection; a first check valve disposed in the first proximal section ofthe first bore, the first check valve being configured to seat againstthe first shoulder and close hydraulic communication from the first portto the second port in response to a first pressure differential acrossthe first check valve, the first check valve being configured to unseatfrom the first shoulder and open hydraulic communication from the secondport to the first port in response to a second pressure differential,opposing the first pressure differential, across the first check valve;and a second check valve disposed in the second proximal section, thesecond check valve configured to seat against the second shoulder andclose hydraulic communication from the second port to the first port inresponse to a third pressure differential across the second check valve,the second check valve being configured to unseat from the secondshoulder and open hydraulic communication from the first port to thesecond port in response to a fourth pressure differential, opposing thethird pressure differential, across the second check valve.
 13. Theapparatus of claim 12, wherein the first and second proximal sectionseach comprise a plug sealing an external opening of the respective borein a respective end of the body.
 14. The apparatus of claim 12, whereinthe first check valve comprises a first poppet having a first proximalside and a first distal side and having a first seal therebetween, thefirst seal engageable with the first shoulder, the first proximal sideexposed to the first proximal section, the first distal side exposed tothe first distal section; and wherein the second check valve comprises asecond poppet having second proximal and distal sides and having asecond seal therebetween, the second seal engageable with the secondshoulder, the second proximal side exposed to the second proximalsection, the second distal side exposed to the second distal section.15. The apparatus of claim 14, wherein the first and second check valveseach comprise a spring disposed in the respective proximal section andbiasing the respective poppet toward the respective seat.
 16. Theapparatus of claim 14, wherein the first and second check valves eachcomprise a cross-flow piece and a spring disposed in the respectiveproximal section, the spring biasing the respective poppet away from thecross-flow piece and toward the respective seat.
 17. The apparatus ofclaim 16, wherein the first and second cross bores each interconnectwith the respective proximal section at the respective cross-flow piece,each cross-flow piece having a central flow passage and a cross-flowpassage therein for hydraulic communication.
 18. The apparatus of claim14, wherein the first and second check valves each comprise a springcollar affixed in the respective proximal section; and a spring disposedin the respective proximal section and biasing the respective poppetaway from the spring collar and toward the respective seat.
 19. Theapparatus of claim 12, wherein the first external port comprises a firstopening of the first proximal section at a first end of the body; andwherein the second external port comprises a second opening of thesecond proximal section at a second end of the body.
 20. The apparatusof claim 19, wherein the first cross bore is defined at a first acuteangle to the first bore, the first cross bore having a first open end tothe first proximal section of the first bore and having a secondopposing open end to the second distal section of the second bore; andwherein the second cross bore is defined at a second acute angle to thesecond bore, the second cross bore having a third open end open to thesecond proximal section of the second bore and having a fourth opposingopen end to the first distal section of the first bore.
 21. Theapparatus of claim 20, wherein the first acute angle of the first crossbore is positioned to clear a first opening at the first end of the bodymade by the first bore; and wherein the second acute angle of the secondcross bore is positioned to clear a second opening at the second end ofthe body made by the second bore.
 22. The apparatus of claim 12, whereinthe first proximal section has a first internal diameter that is greaterthan the first distal section, wherein the first shoulder defines afirst inclined shoulder transitioning from the first proximal second tothe first distal section, the first check valve in the first bore beingsized and configured to seal against the first inclined shoulder. 23.The apparatus of claim 12, wherein the first check valve comprises afirst spring having a first spring rate; and wherein the second checkvalve comprises a second spring having a second spring rate that isdifferent from the first spring rate.
 24. The apparatus of claim 12,wherein the first cross bore communicates a first hydraulic pressure atthe first port to the second pressure differential acting to unseat thefirst check valve from the first shoulder and to the third pressuredifferential acting to seat the second check valve against the secondshoulder; and wherein the second cross bore communicates a secondhydraulic pressure at the second port to the first pressure differentialacting to seat the first check valve against the first shoulder and tothe fourth pressure differential acting to unseat the second check valvefrom the second shoulder.
 25. A subsea hydraulic system for use withfirst and second sources of pressurized hydraulic fluid, the systemcomprising: a hydraulically actuated subsea device disposed in hydrauliccommunication with the first source of pressured hydraulic fluid; asubsea valve apparatus according to claim 1 disposed in hydrauliccommunication with the hydraulically actuated subsea device; and asubsea port disposed in hydraulic communication with the subsea valveapparatus and being configured for disconnectable connection to thesecond source of pressurized hydraulic fluid.
 26. The system of claim25, further comprising at least one shuttle valve disposed in fluidcommunication between the hydraulically actuated subsea device and thesubsea valve apparatus.
 27. The system of claim 25, wherein thehydraulically actuated subsea device comprises a blowout preventer. 28.The system of claim 25, wherein the subsea port is configured fordisconnectable connection to a remotely operated vehicle (ROV) as thesecond source.